Automatic splicing system and method

ABSTRACT

A system for automatic web splicing, comprises of an unwinding section, a splicing section, an accumulator, and a controller to facilitate clamping, cutting and splicing of the webs to provide continuous web supply to a utilizing machine, the system comprises also at least two receiving platforms, a space defining a splicing area between the delivering platform and the receiving platform, one platform for receiving a running web and other platform for a new web and at least one dispenser so as to splice trailing edge of a running web and a leading edge of a new web with an adhesive tape. The system joins the two webs in completely auto mode and keeps the utilizing machine running continuously without stoppage.

FIELD OF THE INVENTION

The present invention generally relates to a splicing system forproviding continuous web supply and a method thereof.

BACKGROUND OF THE INVENTION

Continuous flow of web is required in paper and plastic laminatemanufacturing process and preferably for printing. Accordingly, leadingedge of a new roll of web is spliced with the trailing edge of an oldweb.

Traditionally, splicing of webs is achieved by manually/automaticallyjoining the trailing edge of the old web with leading edge of a new webfrom webs being unwound from rolls carried on cores. The splicing isdone by applying adhesive over trailing end or leading end and joiningby overlapping the web or by using an adhesive tape to join the two endswith overlap or butt splicing.

To carry out such splicing manually, either subsequent machine isstopped or requires slowing down of the subsequent machine and use of anaccumulator considering the time required to splice the webs. Moreover,in web-printing, precision plays important role in splicing as incorrectsplicing may lead to improper printing registration resulting inrejections. Furthermore, the overlapping splicing method has a seriousdisadvantage since the thickness of the web increases at the overlappedportion, the variation in thickness effects coating or printing resultswhen the web is fed through a coating or printing machine.

U.S. Pat. No. 6,016,989 granted in the year 2000 discloses a ‘Paper WebAutosplicer’ to produce a double-sided web splice for paper webs.However, in this patent the leading and trailing edges are required tobe settled downwardly under their own weight onto the adhesive face ofthe tape and hence splicing accuracy depends upon the weight of the web.

Therefore, there is a need for an automatic splicing system and methodto resolve above issues.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides in a first aspect a systemfor automatic web splicing adapted on a running path of a web between anunwinding section and a utilizing machine for providing continuous flowof web to the utilizing machine. The said system comprises at least tworeceiving platforms, one platform for receiving a running web and otherplatform for a new web, a delivering platform for delivering runningweb, a space defining a splicing area between the delivering platformand the receiving platform, an adjusting means for moving, adjusting,and maintaining the delivering platform and one of the receivingplatforms in-line with each other, a clamping means for each platformfor clamping the webs during splicing, a shearing blade for cutting atrailing edge of a finished running web held between the deliveringplatform and the receiving platform by clamping means, at-least onedispenser arranged to travel in cross machine direction within the saidspace so as to splice trailing edge of a running web and a leading edgeof a new web and a controller to facilitate clamping, cutting andsplicing of the webs.

According to one embodiment of the system of the present invention,either receiving platform or delivery platform is mounted on theadjusting means. Advantageously, the receiving platforms are adapted onthe adjusting means for moving and bringing one of the receivingplatform in-line with the delivering platform. Alternatively, thedelivery platform can be adapted on the adjusting means for moving tobring in-line with one of the receiving platform.

According to the present invention, the controller includes a sensor foreach web adapted on the running path of web in the unwinding section tosense and activate the controller as the web is finished.

According to another embodiment of the system of the present invention,the system comprises two dispensers, arranged above and below runningweb within the space to apply adhesive tape from top and bottomsimultaneously. The dispenser comprises a one-sided adhesive tape, arubber roller to apply pressure over the adhesive applied web edges, anda vacuum pad to hold frond end of the adhesive tape having adhesive sidefacing towards the web.

According to one another embodiment of the system of the presentinvention, at-least one of the dispensers includes a cutter for cuttingthe adhesive tapes after splicing. Advantageously, the cutter is adaptedin a top dispenser to cut the adhesive tape after splicing.

According to further embodiment of the system of the present invention,the system comprises a holding means for holding corners of the leadingedge of a new web and the trailing edge of a finished web and front edgeof the adhesive tape together while splicing the webs.

According to further another embodiment of the system of the presentinvention, the system optionally comprises an accumulator to accumulatethe spliced web enough to supply web continuously to the utilizingmachine during splicing operation.

In a second aspect, the present invention provides a method forautomatic web splicing comprising the steps of sensing that running webcore is finished, clamping the finished web using clamping means,cutting the finished web; aligning and adjusting leading edge of a newweb in-line with a trailing edge of the finished web, applying anadhesive tape over the aligned webs and pressing the applied adhesivetape simultaneously, and cutting the adhesive tape thereby effecting thesplicing of the web.

In preferred embodiment of the method of the present invention, the stepof applying adhesive tape includes a step of holding the corners of theleading edge of a new web and the trailing edge of a finished web andfront edge of the adhesive tape.

According to the present invention, the method preferably appliesadhesive tape on top and bottom of the webs simultaneously.

According to the present invention the splicing speed of the system isdependent on speed of an utilizing machine.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will be made to embodiments of the invention, examples ofwhich may be illustrated in the accompanying figures. These figures areintended to be illustrative, not limiting. Although the invention isgenerally described in the context of these embodiments, it should beunderstood that it is not intended to limit the scope of the inventionto these particular embodiments.

The above and other objects, features and advantages of the presentinvention will be more clearly understood from the following detaileddescription taken in conjunction with the accompanying drawing, inwhich:

FIG. 1 shows an automatic splicing system according to the presentinvention;

FIG. 2 shows a block diagram of automatic splicing system according tothe present invention;

FIG. 3 shows a splicing section of the automatic splicing systemaccording to the present invention;

FIG. 4 shows a top dispenser as per a preferred embodiment of thepresent invention;

FIG. 5A-5D shows side views of splicing section of the automaticsplicing system of the present invention, where:

FIG. 5A shows a position of the dispenser before moving in cross machinedirection;

FIGS. 5B and 5C shows movements of dispenser after moving incross-machine direction;

FIG. 5D shows a position of dispenser moving in opposite cross-machinedirection after tape pasting.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the preferred embodiments of the present invention will bedescribed in detail with reference to the accompanying drawings.Reference now should be made to the drawings, in which the samereference numerals are used throughout the different drawings todesignate the same or similar components.

The present invention provides a system for automatic web splicing forproviding continuous flow of web to a utilizing machine. The systemjoins the two webs in completely auto mode and keeps the utilizingmachine running continuously without stoppage.

FIG. 1 and FIG. 2 show an automatic web splicing system according to apreferred embodiment of the present invention.

The automatic splicing system (100) comprises an unwinding section(110), a splicing section (120), an accumulator (130) and a controller(140) to facilitate clamping, cutting and splicing of the webs toprovide continuous web supply to a utilizing machine.

As shown in FIG. 1, the unwinding section (110) comprises two spindles(112 a, 112 b) for mounting web cores (114 a, 114 b) and two runningpaths (a, b) guiding the webs (115 a, 115 b) to splicing section.Sensors (116 a, 116 b) are mounted on the running path of each web (115a, 115 b). For sake of explanation, webs adapted to the web cores (114a, 114 b) may be referred as running web (115 a) and new web (115 b).Further, as shown in FIG. 1, the system comprises of an accumulator(130). The accumulator (130) is adapted generally below the splicingsection (120) to accumulate the web (115) enough to supply the webcontinuously to a utilizing machine to avoid the stoppage of machine.

FIG. 3 and FIG. 5 show the splicing section as per a preferredembodiment of the present invention.

Referring at this point to FIG. 3 which shows the splicing section (120)comprising of a delivering platform (124) and at-least two receivingplatforms (122 a, 122 b)—a first receiving platform (122 a) for arunning web (115 a) and a second receiving platform (122 b) for a newweb (115 b), and a shearing blade (127) for cutting a trailing edge of afinished running web (115 a) held between the receiving and deliveringplatform by clamping means (125 a, 125 b, 125). The clamping means (125a, 125 b, 125) clamp the webs while splicing the webs.

Further, the delivering platform (124) and receiving platforms (122 a,122 b) are adjusted and maintained in-line with each-other via anadjusting means. The adjusting means moves the platform preferably in avertical direction. According to the present invention, the receivingplatforms (122 a, 122 b) or the delivering platform (124) may be adaptedto the adjusting means. As shown in the FIG. 3, and as per the preferredembodiment of the invention, the delivering platform (124) is fixed andthe receiving platforms (122 a, 122 b) are movable by adapting it to theadjusting means for moving and bringing one of the receiving platforms(122 a, 122 b) in-line with the delivering platform (124) for splicing.As shown, a space (x) defines a splicing area between the receivingplatform (122 a, 122 b) and the delivering platform (124) depending onwidth of an adhesive tape. According to the invention, the adhesive tapeis dispensed from at-least one dispenser. According to the presentinvention, the splicing system comprises two dispensers arranged aboveand below the space defined between the delivering and receivingplatforms.

FIG. 4 shows the top dispenser (128 a) of the present invention. Thedispenser (128 a) comprises one side adhesive tape roll (10 a), a rubberroller (20 a) to apply pressure and a vacuum pad (22) to hold adhesiveof the adhesive tape facing towards the web. As shown in FIG. 4, acutter (129) is also adapted in the top dispenser to cut the adhesivetape (10 a). Alternatively, a cutter can be adapted in the bottomdispenser.

FIGS. 5A to 5D show side views of operation of an automatic splicingsystem as per a preferred embodiment of the present invention showingdispensers (128 a, 128 b) adapted on a rod-less cylinder unit to allowthe dispensers to move in a cross-machine direction for splicing. FIGS.5A to 5D also shows holding means (127) for holding corners of theleading edge of a new web and the trailing edge of a finished web andfront edge of the adhesive tape together while splicing the webs. Asshown, each dispenser (128 a, 128 b) comprises one side adhesive taperoll (10 a, 10 b), a rubber roller (20 a, 20 b) to apply pressure, and avacuum pad (22) to hold front end of the adhesive tape (10 a, 10 b)facing towards the web. A cutter (129) is adapted in one of thedispenser to cut the adhesive tape (10 a, 10 b) to cut the adhesive tapeafter splicing.

FIG. 1 and FIG. 5A-5D illustrates operability method of the automaticsplicing system, wherein, a web core (114 a) mounted on spindle (112 a)is running through a first receiving platform (122 a), deliveringplatform (124) and accumulator (130), while web core (114 b) mounted onanother spindle (112 b) is readily mounted on the second receivingplatform (122 b). During this period, the splicing section (120) isinactive as showing in FIG. 5A and allows the running web (115 a) topass to a utilizing machine.

As the running web (115 a) on web core (114 a) finishes, the sensor (116a) mounted on the running path of the unwinding section for said web(115 a) senses that the web (115 a) on the core (114 a) is finished andaccordingly passes the information to the controller (140) whichactivates the clamps (125 a) on receiving platform (122 a) and the clamp(125) on delivering platform (124) to clamp the running web as well asactivates the accumulator (130). As soon as the web (115 a) is clampedbetween the two clamps, the shearing blade (126) activates and crosscuts the clamped web. After cutting, an adjusting means moves thereceiving platforms (122 a, 122 b) so as to adjust the receivingplatform (122 b) in-line with the delivering platform (124) therebybringing leading edge of the new web (115 b) in-line with the cut edgei.e. trailing edge of the finished web. The dispensers (128 a, 128 b)then moves in cross machine direction on the rod-less cylinder unit asshown in FIGS. 5B and 5C, and comes in contact with the holding means(127) which hold the free edges of the adhesive tapes (10 a, 10 b)having adhesive face over the edges of the leading and trailing web fromlongitudinal side of the webs and then dispensers (128 a, 128 b) movesin the opposite direction as shown in FIG. 5D applying the adhesive tape(10 a, 10 b) and pressing the adhesive tape simultaneously by rubberrollers (20 a, 20 b) applied over the web edges thereby butt splicingthe web edges from both sides i.e. top and bottom side. On splicing, thecutter (129) adapted in the upper dispenser (128 a) cuts the adhesivetape and splicing is completed thereby forming a continuous web. Aftercompletion of the splicing, clamps over the running web frees the weband the machine starts drawing of web from the new web core. Similarly,when a running roll is processed and finished, the sensor passes asignal to the controller and the controller changeovers to a new web byclamping, cutting and splicing the running web with next web and keepsthe machine running.

According to the present invention the splicing speed of the systemdepends upon speed of the utilizing machine. In this aspect, thesplicing system does not require its own drive. For example, for alaminate printing machine operating at tension 5 kg and having aprinting speed of 80 meters/min, splicing system of the presentinvention requires total cycle time of about 4 to 6 seconds depending onwidth of web for splicing.

Advantageously, the present invention provides auto splicing along withincrease in machine up time, reduction in scarp, reduction in man-hours,improved quality of joint, elimination of paper shifting, as well aselimination of breakage of papers by providing a quality of joint onboth side of the web along with improved strength. Further, the splicingsystem of the present invention is a compact machine which can be easilyadapted to on an in-use continuous plastic or paper web processingmachine without major modifications.

1. A system for automatic web splicing adapted on a running path of aweb between an unwinding section and a utilizing machine for providingcontinuous flow of web to the utilizing machine, said system comprising:at least two receiving platforms, one platform for receiving a runningweb and other platform for a new web; a delivering platform fordelivering running web; a space defining a splicing area between thedelivering platform and the receiving platform; an adjusting means formoving, adjusting, and maintaining the delivering platform and one ofthe receiving platforms in-line with each other; a clamping means foreach platform for clamping the webs during splicing; a shearing bladefor cutting a trailing edge of a finished running web held between thedelivering platform and the receiving platform by clamping means;at-least one dispenser arranged to travel in cross machine directionwithin the said space so as to splice trailing edge of a running web anda leading edge of a new web with an adhesive tape; and a controller tofacilitate clamping, cutting and splicing of the webs.
 2. A system forautomatic web splicing as claimed in claim 1, wherein the receivingplatforms is adapted on the adjusting means for moving and bringing oneof the receiving platform in-line with the delivering platform.
 3. Asystem for automatic web splicing as claimed in claim 1, wherein thedelivering platform is adapted on the adjusting means for moving andbringing in-line the delivering platform with one of the receivingplatform.
 4. A system for automatic web splicing as claimed in claim 1wherein the controller includes a sensor for each web adapted on therunning path of web in the unwinding section to sense and activate thecontroller as the web is finished.
 5. A system for automatic websplicing as claimed in claim 1, wherein the dispenser comprises aone-sided adhesive tape, a rubber roller to apply pressure over theadhesive applied web edges, and a vacuum pad to hold front end of theadhesive tape having adhesive side facing towards the web.
 6. A systemfor automatic web splicing as claimed any one of the preceding claims,wherein the system preferably comprises two dispensers, arranged aboveand below running web within the space to apply adhesive tape from topand bottom simultaneously.
 7. A system for automatic web splicing asclaimed in claim 6, wherein at-least one of the dispensers includes acutter for cutting the adhesive tape after splicing the webs.
 8. Asystem for automatic web splicing as claimed in claim 7, wherein thecutter is preferably adapted in a top dispenser to cut the adhesive tapeafter splicing.
 9. A system for automatic web splicing as claimed inclaim 1, wherein the system comprises a holding means for holdingcorners of the leading edge of a new web and the trailing edge of afinished web and front edge of the adhesive tape together while splicingthe webs.
 10. A system for automatic web splicing as claimed in claim 1,wherein the adjusting means moves the platform preferably in a verticaldirection.
 11. A system for automatic web splicing as claimed in claim 1further comprises an accumulator to accumulate the spliced web enough tosupply web continuously to the utilizing machine during splicingoperation.
 12. A system for automatic web splicing as claimed in claim1, wherein the unwinding section comprises a spindle corresponding toeach receiving platform for mounting a web core of running web and a webcore of new web, a running path for each web.
 13. A method for automaticweb splicing comprising the steps of: sensing that running web core isfinished; clamping the finished web using clamping means; cutting thefinished web; aligning and adjusting leading edge of a new web in-linewith a trailing edge of the finished web; applying an adhesive tape overthe aligned webs and pressing the applied adhesive tape simultaneously;and cutting the adhesive tape thereby effecting the splicing of the web.14. A method for automatic web splicing as claimed in claim 13, whereinthe step of applying adhesive tape includes a step of holding thecorners of the leading edge of a new web and the trailing edge of afinished web and front edge of the adhesive tape.
 15. A method forautomatic web splicing as claimed in claim 13, wherein the adhesive tapeis preferably applied on top and bottom of the webs simultaneously. 16.A method for automatic web splicing as claimed in claim 13, whereinspeed of splicing is dependent on speed of an utilizing machine.